Multimatic 255 MIG/Multiprocess Power Source, Wire Feeder and Gun Package Issued Nov. 2018 Index No. DC/12.9 Quick Specs Industrial Applications Contract welding services Plant maintenance shops General fabricators Processes MIG (GMAW) Pulsed MIG (GMAW-P) Flux-cored (FCAW) DC stick (SMAW) DC Lift-Arc TIG (GTAW) Pulsed TIG (GTAW-P) Input Power Auto-Line 208 575 V, single-phase Rated Output MIG: 230 A at 25.5 V, 60% duty cycle Stick: 200 A at 28 V, 60% duty cycle TIG: 275 A at 21 V, 60% duty cycle Amperage Range 5 350 A Net Weight Machine only: 84 lb. (38 kg) Machine with running gear: 148 lb. (67 kg) Easy to Use. Versatility. Portability. Built for professionals in the MRO and light manufacturing/ fabrication segments who want a smaller, versatile welder with intuitive setup to increase efficiencies and productivity. This 250-amp inverter multiprocess welder is easy to use, will deliver versatility for faster uptime and performance, while allowing for portability. Easy to Use MATERIAL THICKNESS Quick and easy setup Versatility MULTIPROCESS (MIG, STICK, DC TIG) Machine only Multiple processes with only one machine Machine with running gear Portability MACHINE ONLY WEIGHS 84lb. Portable Welder is warranted for three years, parts and labor. Gun warranted for 90 days, parts only. Miller Electric Mfg. LLC An ITW Welding Company 1635 West Spencer Street P.O. Box 1079 Appleton, WI 54912-1079 USA Equipment Sales US and Canada Phone: 866-931-9730 FAX: 800-637-2315 International Phone: 920-735-4554 International FAX: 920-735-4125 MillerWelds.com
Multimatic 255 Features and Benefits Easy to Use Pulsed MIG setup screen Connection screen for MIG process using C10 gas Easy-to-understand interface with 7-inch color LCD display ensures proper machine setup and parameter selection, reducing setup time and increasing weld time. Quick-access process and weld mode backlit buttons across the top illuminate when active. Soft-key buttons below the display change function depending on which screen is displayed. Makes setup or change quick, easy and intuitive. Large text for easier readability. Intuitive connection setup images. Full troubleshooting descriptions versus help errors and look up codes. Auto-Set Elite offers predefined weld settings to increase ease of use and ensure that the job is done right for operators of all skill levels. Available for MIG, pulsed MIG, stick and DC TIG processes with the ability to fine-tune your settings. Set weld parameters by selecting: MIG (shown) wire and gas type, wire diameter and material thickness Stick electrode type, electrode diameter and material thickness DC Lift-Arc TIG remote on/off, tungsten diameter and material thickness Program mode allows easy save and recall of favorite weld settings. Save up to four programs for each process. Deliver more productivity by eliminating need to manually set parameters. Deliver consistent quality by welders of all skill levels with prequalified settings. Minimize supervisor intervention. MDX-250 MIG gun with AccuLock S consumable system features a dual-locked, front-loading liner that optimizes wire feedability. Install AccuLock contact tips with a single turn. AccuLock liner locks at front and back of gun to align with contact tip and power pin for a flawless wire feed path. Durable, ergonomic handle with overmolding improves grip and comfort. Ball-and-socket handle with rear swivel for increased gun maneuverability while reducing welder fatigue. AccuL ck TM Optional EZ-Select MIG gun MDX-250 EZ-Select MIG gun has four LEDs on the back of the gun handle to indicate which program is selected. Simply tap gun trigger to select the program. The number of lit LEDs on gun indicate the selected program. No more going back to machine to change weld settings. No more having to move to see settings when front panel of machine is obstructed. 2
Multimatic 255 Features and Benefits Versatility MULTIPROCESS (MIG, STICK, DC TIG) Multiprocess capabilities include MIG, flux cored, DC stick (6010) and DC Lift-Arc TIG welding. The Multimatic 255 also has pulsing capability that allows it to do pulsed MIG and TIG welding. Compatible with push-pull MIG guns. Increases productivity by allowing the use of 12-inch wire spools versus a spool gun s 4-inch spools. Reduces downtime from changing wire spools. Auto-Gun Detect automatically adjusts voltage, wire speed and timers for faster switching between MIG, push-pull and spool guns. For portability and reliability Auto-Line allows for any single-phase input voltage hookup (208 575 V) with no manual linking, providing convenience in any job setting. Ideal solution for dirty or unreliable power. Pulsed MIG welding delivers higher quality welds for ALL welders. Lower heat input for less distortion on thin materials and better puddle control on out-of-position welds. Less spatter minimizes post weld grinding and rework, allowing more welding time. Perform welding applications that couldn t be done in the past. Ideal for MIG welding aluminum and stainless steel. Best For Standard Spray Pulsed MIG Short Circuit Gap Filling D B A Low Heat Input D B A Out-of-Position Welds A B Low Spatter A A C Thick Metals A A D Thin Metals B A Increased Travel Speed A A B Aluminum MIG Welding C A C HOT COLD Ratings A, B, C, and D are relative values. An A rating indicates a best fit between your performance needs and process. A blank rating indicates that the process is not recommended for that application. Portability MACHINE ONLY WEIGHS 84lb. Weight is reduced by more than 50 percent compared to the Millermatic 252. Optional EZ-Latch running gear EZ-Latch running gears are available in single cylinder and dual cylinder models (included with package or can be ordered separately). Operators no longer need to lift machine AND running gear into the truck. Latches secure machine to running gear. Simply loosen the latch retaining knob and rotate latches to disengage machine from running gear for easy portability. Cylinder racks feature bottle forward technology for increased stability when moving along an incline and running gears have built-in storage for accessories. Dual cylinder model includes an elevated gun and cable rack to keep cables off the floor and tangle free. Bottle forward technology Dual cylinder model includes elevated gun and cable rack Storage solution Single cylinder running gear Latches shown in open position without machine and in closed position securing the machine Dual cylinder running gear 3
Specifications (Subject to change without notice.) Welding Process CV: MIG/ flux-cored CC: Stick CC: DC TIG Welding Amperage Range 20 350 A 30 275 A 5 275 A Rated Output 230 A at 25.5 V, 60% duty cycle 200 A at 28 V, 60% duty cycle 275 A at 21 V, 60% duty cycle Amps Input at Rated Output, 50/60 Hz 208 V 240 V 460 V 575 V KVA KW 34.7 29.7 17.1 14.3 8.2 8.2 33.5 29 16.4 13.6 7.8 7.8 34.1 29.9 17 14.1 8.1 8.1 Wire Feed Speed 50 800 ipm (1.3 20 m/min.) Max. Open- Circuit Voltage 81 VDC Dimensions Machine only H: 19.24 in. (489 mm) W: 13.75 in. (349 mm) D: 26.25 in. (667 mm) Machine with running gear H: 32 in. (813 mm) W: 13.75 in. (349 mm) D: 45 in. (1,143 mm) Net Weight Machine only 84 lb. (38 kg) Machine with running gear 148 lb. (67 kg) Certified by Canadian Standards Association to both the Canadian and U.S. Standards. Control Panel Performance Data 1 2 3 4 5 7 8 9 Weld Amperes 400 350 300 250 200 150 100 MIG Duty Cycle Chart 50 6 10 0 10 15 20 25 30 40 50 60 70 80 90 100 % Duty Cycle 400 Stick Duty Cycle Chart 1. TIG Process Button 2. Stick Process Button 3. MIG Process Button 4. USB Port 5. Color LCD Display 6. Left Adjustment Knob (Adjusts voltage, arc length, pulse frequency or parameter values depending on mode.) 7. Auto-Set Button 8. Pulse Button 9. Power Switch 10. Right Adjustment Knob (Adjusts wire feed speed, amperage or parameter values depending on mode.) 11. Soft Keys (Multiple functions depending on screen displayed.) 11 Weld Amperes Weld Amperes 350 300 250 200 150 100 50 0 10 15 20 25 30 40 50 60 70 80 90 100 % Duty Cycle 400 350 300 250 200 150 TIG Duty Cycle Chart 100 50 0 10 15 20 25 30 40 50 60 70 80 90 100 % Duty Cycle 4
Multimatic 255 Packages 907728 Machine only Comes complete with: Power source with 10 ft. (3 m) industrial power cord 15 ft. (4.5 m) 250-amp MDX -250 MIG gun with Bernard AccuLock S consumables for.035/.045 in. (0.9/1.2 mm) wire 10 ft. (3 m) cable with electrode holder and 50 mm Dinse-style connector 10 ft. (3 m) work cable with clamp and 50 mm Dinse-style connector Flow gauge regulator and gas hose for argon or AR/CO 2 mix.035/.045 in. (0.9/1.2 mm) reversible drive rolls Extra contact tips Material thickness gauge 951767 Machine with running gear package Comes complete with: Power source with 10 ft. (3 m) industrial power cord 15 ft. (4.5 m) 250-amp MDX -250 MIG gun with Bernard AccuLock S consumables for.035/.045 in. (0.9/1.2 mm) wire 10 ft. (3 m) cable with electrode holder and 50 mm Dinse-style connector 10 ft. (3 m) work cable with clamp and 50 mm Dinse-style connector Flow gauge regulator and gas hose for argon or AR/CO 2 mix.035/.045 in. (0.9/1.2 mm) reversible drive rolls Extra contact tips Material thickness gauge EZ-Latch single cylinder running gear Chain to secure gas cylinder 951768 Machine with dual cylinder/ TIG kit package Comes complete with: Power source with 10 ft. (3 m) industrial power cord 15 ft. (4.5 m) 250-amp MDX -250 MIG gun with Bernard AccuLock S consumables for.035/.045 in. (0.9/1.2 mm) wire 10 ft. (3 m) cable with electrode holder and 50 mm Dinse-style connector 10 ft. (3 m) work cable with clamp and 50 mm Dinse-style connector Flow gauge regulator and gas hose for argon or AR/CO 2 mix.035/.045 in. (0.9/1.2 mm) reversible drive rolls Extra contact tips Material thickness gauge EZ-Latch dual cylinder running gear with elevated gun and cable rack Multimatic 255 TIG kit Two chains to secure gas cylinders 5
Genuine Miller Accessories MIG Gun Push-Pull Guns EZ-Latch Single Cylinder Running Gear 301449 Running gear with a single cylinder rack and storage compartment. Latches secure machine to cart. Simply rotate latches to disengage machine from cart for easy portability. EZ-Latch Dual Cylinder Running Gear 951769 Similar to above, but with a dual cylinder rack which allows operator to easily store two gas cylinders. Includes elevated gun and cable rack (shown below) to keep cables off the floor and tangle free. MDX -250 MIG Gun 1770041 10 ft. (3 m) 1770042 12 ft. (3.7 m) 1770043 15 ft. (4.6 m), standard Industrial 250-amp MIG gun with Bernard AccuLock S consumables for.035/.045 in. (0.9/1.2 mm) wire. MDX -250 EZ-Select MIG Gun 1770046 15 ft. (4.6 m) Similar to above, but with four LEDs on gun handle to indicate which machine program is selected. Tap trigger to select program. Allows operator to know which program is being used without going back to machine. Spool Guns Spoolmatic 15A Spool Gun 195156 Spoolmatic 30A Spool Gun 130831 Ideal for aluminum welding jobs. Air-cooled, one-pound spool gun with 15-foot (4.6 m) or 30-foot (9.1 m) cable assembly. Rated at 200 amps at 100 percent duty cycle. For detailed information, see Spoolmatic literature M/1.73. XR-Aluma-Pro Push-Pull Gun 300000 15 ft. (4.6 m) 300001 25 ft. (7.6 m) Air-cooled gooseneck-style gun for.030.047 inch (0.8 1.2 mm) aluminum. Rated at 300 amps at 100 percent duty cycle. XR-Aluma-Pro Lite Push-Pull Gun 300948 25 ft. (7.6 m) Air-cooled gooseneck-style gun for.030.047 inch (0.8 1.2 mm) aluminum. Rated at 175 amps at 60 percent duty cycle. U-Grooved Aluminum Drive Roll and Accessory Kits for XR-Aluma-Pro Push-Pull Guns 195311.035 in. (0.9 mm) 195312.040 in. (1 mm) 195313.047 in. (1.2 mm) Kits include Multimatic U-grooved drive rolls, nylon wire guides and contact tips. EZ-Latch Dual Cylinder Rack with Elevated Gun and Cable Rack 301481 Converts an EZ-Latch single cylinder running gear into a dual cylinder rack to easily store two gas cylinders. Gun and cable rack keeps cables off the floor and tangle free. (Included with EZ-Latch dual cylinder running gear.) Protective Cover 301521 Features side pocket. Argon/Mixed Gas Regulator and Gas Hose 195050 Spoolmate 200 Spool Gun 300497 Reliable and economical spool gun perfect for hobbyists and light fabricators who weld aluminum. Handles.030.035 inch (0.8 0.9 mm) aluminum wires and.023.035 inch (0.6 0.9 mm) steel/stainless steel wires. Rated at 160 amps, 60 percent duty cycle with 20-foot cable assembly. For detailed information, see Spoolmate literature M/1.47. Optional Spoolmate 200 Head Tubes 300591 45-degree head tube 300592 9-inch extension head tube 243385 5-inch head tube 6
Genuine Miller Accessories Multimatic 255 TIG Kit 301518 Kits comes complete with everything needed to TIG weld with the Multimatic 255. Includes 25-foot (7.6 m) Weldcraft A-150 TIG torch, RFCS-14 HD foot control, 10-pin to 14-pin adapter cord, flow gauge regulator with 5-foot (1.5 m) gas hose, and AK1C torch accessory kit. Remote Controls Wireless Remote Foot Control 300429 For remote current and contactor control. Receiver plugs directly into the 14-pin receptacle of Miller machine. 90-foot (27.4 m) operating range. Consumables For MDX -250 MIG Guns Standard Bernard AccuLock S Consumables Consumables for increased durability and longer life when guns are used in industrial applications. Contact Tips (10 per package) T-A023CH.023 in. (0.6 mm) T-A030CH.030 in. (0.8 mm) T-A035CH.035 in. (0.9 mm) T-A039CH.039 in. (1.0 mm) T-A045CH.045 in. (1.2 mm) Nozzle N-A5800C Copper, 5/8 in. orifice, flush Diffuser D-MA250 Monocoil Replacement Liners 10 ft. Liner LM1A-10.023/.025 in. (0.6 mm) LM2A-10.030/.035 in. (0.8/0.9 mm) LM3A-10.035/.045 in. (0.9/1.2 mm) 12 ft. Liner LM1A-12.023/.025 in. (0.6 mm) LM2A-12.030/.035 in. (0.8/0.9 mm) LM3A-12.035/.045 in. (0.9/1.2 mm) 15 ft. Liner LM1A-15.023/.025 in. (0.6 mm) LM2A-15.030/.035 in. (0.8/0.9 mm) LM3A-15.035/.045 in. (0.9/1.2 mm) Note: Miller FasTip, M-Series and Bernard Centerfire diffusers and consumables are not compatible with MDX Series guns. Wireless Remote Hand Control 300430 For remote current and contactor control. Receiver plugs directly into the 14-pin receptacle of Miller machine. 300-foot (91.4 m) operating range. RFCS-14 HD Foot Control 194744 Maximum flexibility is accom plished with a reconfigurable cord that can exit the front, back or either side of the pedal. Foot pedal provides remote current and contactor control. Includes 20-foot (6 m) cord with 14-pin plug. RHC-14 Hand Control 242211020 Miniature hand control for remote current and contactor control. Dimensions: 4 x 4 x 3.25 inches (102 x 102 x 82 mm). Includes 20-foot (6 m) cord with 14-pin plug. For Spoolmatic Spool Guns and XR Push-Pull Guns For Aluminum Wire FasTip Contact Tips (25 per package) 206186 Heavy-duty,.030 in. (0.8 mm) 206187 Heavy-duty,.035 in. (0.9 mm) 206188 Heavy-duty,.040 in. (1.0 mm) 206189 Heavy-duty, 3/64 in. (1.2 mm) 206191 Heavy-duty, 1/16 in. (1.6 mm) 209026 Tapered,.030 in. (0.8 mm) 209027 Tapered,.035 in. (0.9 mm) 209029 Tapered, 3/64 in. (1.2 mm) 206030 Tapered, 1/16 in. (1.6 mm) Screw-On Nozzles 199610 Brass, 1/2 in. orifice, tapered 199611 Brass, 3/4 in. orifice, straight 199612 Brass, 3/4 in. orifice, straight HD 199613 Brass, 5/8 in. orifice, tapered 199614 Brass, 5/8 in. orifice, tapered HD 199615 Copper, 1/2 in. orifice, tapered 199616 Copper, 3/4 in. orifice, straight 199617 Copper, 3/4 in. orifice, straight HD 198855 Copper, 5/8 in. orifice, tapered 199618 Copper, 5/8 in. orifice, tapered HD 207313 Copper, 5/8 in. orifice, tapered 15/16 OD 209035 Copper, 3/8 in. orifice, tapered 209036 Copper, 1/2 in. orifice, tapered RCC-14 Remote Contactor and Current Control 151086 East/west rotary-motion fingertip control attaches to TIG torch using two hook-and-loop fasteners. Includes 26.5-foot (8 m) cord with 14-pin plug. RCCS-14 Remote Contactor and Current Control 043688 North/south rotary-motion fingertip control attaches to TIG torch using two hook-and-loop fasteners. Includes 26.5-foot (8 m) cord with 14-pin plug. 10-Pin to 14-Pin Adapter Cord 273873 Allows standard 14-pin TIG remote controls to be used with the Multimatic 255. Bernard Centerfire T Series Contact Tips T-035AL.035 in. (0.9 mm) T-047AL.047 in. (1.2 mm) T-062AL 1/16 in. (1.6 mm) Bernard Centerfire Small Nozzles NS-5818B Brass, 5/8 in. ID, 1/8 in. tip recess NS-1218B Brass, 1/2 in. ID, 1/8 in. tip recess NS-1218C Copper, 1/2 in. ID, 1/8 in. tip recess NS-1200B Brass, 1/2 in. ID, flush tip NST-3818B Brass, 3/8 in. ID, 1/8 in. tip recess For Spoolmate 200 Spool Gun Note: Spoolmate 200 spool gun ships with (2).030 in. and (2).035 in. contact tips and (1) nozzle. For Standard Heavy-Duty Head Tube Contact Tips (5 per package) 199387.030 in. (0.8 mm) 199388.035 in. (0.9 mm) Nozzle 050622 For Optional Head Tubes Note: The same consumables are used on 45-degree, 5-inch, and 9-inch extension head tubes. Contact Tips (5 per package) 199730.024 in. (0.6 mm) (requires V-knurled drive roll 136135) 186419.030 in. (0.8 mm) 186406.035 in. (0.9 mm) Nozzle 186405 7
Consumables (Continued Order from Miller Service Parts.) For Multimatic 255 Note: Machine drive roll kits include two drive rolls and an inlet guide. V-Grooved Drive Roll Kits (solid wire) 204579.030 and.035 in. (0.8 and 0.9 mm) combination (reversible) 087131.024 in. (0.6 mm) 079594.030 in. (0.8 mm) 079595.035 in. (0.9 mm) 079596.045 in. (1.2 mm) V-Knurled Drive Roll Kits (flux-cored or difficult-to-feed wire) 079606.035 in. (0.9 mm) 079607.045 in. (1.2 mm) 079608.052 in. (1.3 mm) U-Grooved Drive Roll Kits (aluminum wire) 044749.035 in. (0.9 mm) 079599.047 in. (1.2 mm) Ordering Information Power Source and Options Stock No. Description Qty. Price Multimatic 255 907728 Auto-Line 208 575 V, 50/60 Hz Multimatic 255 with Running Gear 951767 Auto-Line 208 575 V, 50/60 Hz with single cylinder running gear Multimatic 255 with Dual Cylinder/TIG Kit 951768 Accessories Auto-Line 208 575 V, 50/60 Hz with dual cylinder running gear and TIG kit EZ-Latch Single Cylinder Running Gear 301449 Running gear with single cylinder rack EZ-Latch Dual Cylinder Running Gear 951769 Running gear with dual cylinder rack and elevated gun and cable rack EZ-Latch Dual Cylinder Rack 301481 Upgrade single cylinder rack to dual with Elevated Gun and Cable Rack (included with EZ-Latch dual cylinder running gear) Protective Cover 301521 Features side pocket Argon/Mixed Gas Regulator and Gas Hose 195050 MIG Guns MDX -250 MIG Gun 1770041 10 ft. (3 m), 250 A,.035/.045 in. (0.9/1.2 mm) wire 1770042 12 ft. (3.7 m), 250 A,.035/.045 in. (0.9/1.2 mm) wire 1770043 15 ft. (4.6 m), 250 A,.035/.045 in. (0.9/1.2 mm) wire MDX -250 EZ-Select MIG Gun 1770046 15 ft. (4.6 m), 250 A,.035/.045 in. (0.9/1.2 mm) wire Spoolmatic 15A Spool Gun 195156 15 ft. (4.6 m), 200 A,.030.047 in. (0.8 1.2 mm) for aluminum wire Spoolmatic 30A Spool Gun 130831 30 ft. (9 m), 200 A,.030.047 in. (0.8 1.2 mm) for aluminum wire Spoolmate 200 Spool Gun 300497 20 ft. (6 m), 160 A,.030.035 in. (0.8 0.9 mm) for aluminum wire,.023.035 in. (0.6 0.9 mm) for steel/stainless steel wire Optional Spoolmate 200 Head Tubes See page 6 XR-Aluma-Pro Gun (air-cooled) 300000 15 ft. (4.6 m), 300 A at 100% duty cycle,.030.047 in. (0.8 1.2 mm) for alum. wire 300001 25 ft. (7.6 m), 300 A at 100% duty cycle,.030.047 in. (0.8 1.2 mm) for alum. wire XR-Aluma-Pro Lite Gun (air-cooled) 300948 25 ft. (7.6 m), 175 A at 60% duty cycle,.030.047 in. (0.8 1.2 mm) for alum. wire TIG Accessories Multimatic 255 TIG Kit 301518 Includes Weldcraft A-150 TIG torch, RFCS-14 HD foot control, 10-pin to 14-pin adapter cord, flow gauge regulator with gas hose, and AK1C torch accessory kit Wireless Remote Foot Control 300429 Foot control with wireless 90 ft. (27.4 m) operating range Wireless Remote Hand Control 300430 Hand control with wireless 300 ft. (91.4 m) operating range RFCS-14 HD 194744 Heavy-duty foot control (included with TIG kit and TIG package) RHC-14 242211020 Hand control with 20 ft. (6 m) cord RCC-14 151086 Fingertip control RCCS-14 043688 Fingertip control 10-Pin to 14-Pin Adapter Cord 273873 Allows standard 14-pin TIG remote controls to be used with the Multimatic 255 Consumables Contact Tips See page 7 Replacement Liners See page 7 Nozzles See page 7 Drive Rolls See page 6 for gun drive rolls and above for machine drive rolls Date: Total Quoted Price: Distributed by: 2018 Miller Electric Mfg. LLC